U-joint vs pot coupler
OK, I finished this column rebuild project. The Borgeson U-joint works great. Below are pics of my solution. I have a '67 dart, so the existing replacement column bearing kits don't fit my column. I built one using the ER-16 bearing as suggested above. I got a piece of 2 1/4" OD pipe and reamed it out to press in the bearing. On the other end, I pressed in some high density polyethylene pipe and reamed it out a bit to fit a ($4) plastic bushing for the shifter tube to ride in. I used screws into the polyethylene to hold the unit in place. To make room for the ER-16, my fabricated piece sticks out of the original column housing about 1/2". I did not need to cut my steering shaft for this to fit, it was just the right size. On my shaft, the ER-16 seated about three quarters of its width on the 1" shaft, and the remaining quarter (where the two set screws set) I used a steel shim to make sure it maintained its proper alignment with the shaft when the set screws were tightened. I replaced the original (long gone) seal on the shift tube with some polyethylene foam pipe insulation, used silicone grease to lube it (regular grease will destroy HDPE) - see green arrow on installed pic. You can also see my reverse switch post redo, it's described above, a fine thread machine screw installed from the inside of the shift tube and a nylon female threaded jacket on the outside (to engage the reverse switch and not damage it). I used Rustoleum textured paint for the finish, same as I used for my Dash.
OK, I finished this column rebuild project. The Borgeson U-joint works great. Below are pics of my solution. I have a '67 dart, so the existing replacement column bearing kits don't fit my column. I built one using the ER-16 bearing as suggested above. I got a piece of 2 1/4" OD pipe and reamed it out to press in the bearing. On the other end, I pressed in some high density polyethylene pipe and reamed it out a bit to fit a ($4) plastic bushing for the shifter tube to ride in. I used screws into the polyethylene to hold the unit in place. To make room for the ER-16, my fabricated piece sticks out of the original column housing about 1/2". I did not need to cut my steering shaft for this to fit, it was just the right size. On my shaft, the ER-16 seated about three quarters of its width on the 1" shaft, and the remaining quarter (where the two set screws set) I used a steel shim to make sure it maintained its proper alignment with the shaft when the set screws were tightened. I replaced the original (long gone) seal on the shift tube with some polyethylene foam pipe insulation, used silicone grease to lube it (regular grease will destroy HDPE) - see green arrow on installed pic. You can also see my reverse switch post redo, it's described above, a fine thread machine screw installed from the inside of the shift tube and a nylon female threaded jacket on the outside (to engage the reverse switch and not damage it). I used Rustoleum textured paint for the finish, same as I used for my Dash.